Solid Oxide Fuel Cell Expanded Metal Substrate
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Solution Overview
Problem
Existing solid oxide fuel cells lack sufficient mechanical and thermal stability, which limits their application in various environments and requires additional components for interconnection and gas supply, increasing complexity and cost.
Innovation Solution
A solid oxide fuel cell with a carrier substrate partially formed from expanded metal and filling materials, such as metallic, inert ceramic, catalytic, or desulphurizing materials, which enhances mechanical and thermal stability, allows for direct reforming and desulfurization, and integrates media guide channels for efficient gas supply, eliminating the need for additional interconnectors and external systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional powder metallurgy is used to produce fuel cell plates, then the manufacturing process is relatively simple, but the mechanical and thermal stability is insufficient
Solution Approach 1:
The patent employs a composite structure consisting of an expanded metal carrier substrate combined with functional layers. The expanded metal provides enhanced mechanical strength and thermal stability, while the functional layers deliver electrochemical activity. This composite approach resolves the contradiction by integrating structural support and functionality into a unified design, eliminating the need for separate interconnector components.
Solution Approach 2:
The invention merges the carrier substrate and interconnector functions into a single integrated component. The expanded metal substrate serves both as the structural foundation for applying functional layers and as the interconnector for stacking fuel cells. This consolidation reduces device complexity while maintaining or improving mechanical and thermal stability.
2Reliability
If additional interconnectors and external systems are added to improve stability, then mechanical and thermal stability increases, but device complexity and production cost increase
Solution Approach 1:
The expanded metal carrier substrate performs multiple functions simultaneously: it provides mechanical support, serves as an interconnector for stacking cells, and offers a substrate for functional layer application. This multi-functionality eliminates the need for separate interconnector components, reducing device complexity and production cost while maintaining reliability.
Solution Approach 2:
The invention combines the carrier substrate and interconnector into a single integrated component. The expanded metal substrate fulfills both structural and connection roles, allowing fuel cells to be stacked directly without additional interconnectors. This merging reduces the number of components and simplifies the overall device structure.
3Strength
If the carrier substrate is made from expanded metal, then mechanical and thermal stability increases, but gas permeability may be reduced
Solution Approach 1:
The patent utilizes expanded metal with an inherently porous structure that provides both mechanical strength and gas permeability. The expansion process creates a three-dimensional network with open cells that allow gas flow while maintaining structural integrity. This porous architecture resolves the contradiction by enabling simultaneous achievement of strength and permeability.
Solution Approach 2:
The expanded metal substrate exhibits local variations in porosity and density that can be optimized for different regions. Areas requiring higher strength can have denser structures, while regions needing better gas flow can have higher porosity. This localized optimization allows the substrate to meet both mechanical and permeability requirements.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution provides a high-performance fuel cell stack with increased mechanical stability, reduced production costs, and improved thermal management, enabling applications in mobile and stationary power generation while maintaining chemical stability and preventing poisoning.
Implementation Method 1
the carrier substrate is at least partially formed from at least one stretching element, in particular expanded metal. This increases the mechanical and thermal stability of the fuel cell.
Implementation Method 2
It is thus possible to achieve particularly high gas permeability by means of a sintering process.
Implementation Method 3
the carrier substrate is formed at least partially from a chromium and/or silicon-reducing filler material, in particular a chromium getter made from Mn 2-x CO 1+x O 4 and/or LaSrMn. As a result, chromium and/or silicon poisoning during operation of the fuel cell can be avoided.
Data Source
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AI summary
The invention relates to a fuel cell (10), in particular a solid oxide fuel cell (12), and to a method for manufacturing such a fuel cell (10), comprising at least one support substrate (14) and a functional layer system (16) applied to the support substrate (14). The fuel cell (10) is characterized in that the support substrate (14) is at least partially formed from at least one expanded metal (18). The invention also relates to a fuel cell stack (60) comprising such a fuel cell (10) and to a method for manufacturing such a fuel cell stack (60).